Top 4 Tips When Installing Ballistic Rubber Blocks (And How to Avoid Costly Mistakes)

Ballistic rubber blocks  perform  well when they are  installed properly. Even premium materials can fail if fitted on uneven surfaces or with poor alignment. These small errors create gaps between blocks,  shorten block life, and risk non-compliance with range safety standards.

TAP Ballistics supports these standards with modular Ballistic Blocks, Trap Rubber, and Ballistic Range Panels, systems engineered to perform when installed correctly.

Here are the five best installation tips when installing ballistic rubber blocks and how to ensure the best performance.  

Tip #1:  Ensure   Surface Preparation and Alignment.

The Problem

Ballistic rubber must sit flush on  a stable, level base. When blocks are installed on uneven, dirty, or gaps between blocks are visible,  they can shift under impact or develop small gaps between joints. These inconsistencies can create hazardous conditions  and undermine the block’s ballistic efficiency.

Why It Matters

Misaligned or unstable foundations reduce energy absorption and cause accelerated wear. Even a small void behind a block can redirect projectiles or trap debris, eventually weakening the system. In worst-case scenarios, this misalignment violates range safety standards outlined in the NRA Range Source Book.

How to Avoid It

🗹 Prepare the substrate: Remove dust, oils, and loose material. Concrete bases should be smooth, level,  and load-bearing.

🗹 Check for level: Use a laser or string-line to confirm surface flatness before placement.

🗹 Use mechanical anchoring: Follow the manufacturer’s specifications for Ballistic Blocks; improper fastening can deform panels or allow shifting.

🗹 Maintain tight alignment: Ensure each block interlocks snugly to form a continuous ballistic surface with no gaps or overlaps.

Thorough surface preparation isn’t just a best practice; it’s the foundation of every safe, compliant ballistic installation.

Tip #2:  : Correct  Anchoring and Spacing

The Problem

Anchoring and spacing errors are among the most overlooked issues during installation. Over-tightened bolts, inconsistent gaps, or makeshift adhesives can cause deformation under ballistic impact. Over time, this leads to separation between blocks or warping that allows projectiles to slip through weak points.

Why It Matters

Gaps or shifting panels create unpredictable ricochet angles and unsafe rebound zones. Poor anchoring can also place extra stress on adjacent blocks.  These problems are preventable but can be  ignored when installation crews lack proper guidance or cut corners to save time.

How to Avoid It

🗹 Follow manufacturer guidelines: Use only the anchoring systems recommended for Ballistic Blocks. Substituting with non-rated bolts or adhesives increases risk.

🗹 Choose blocks that fit snug as you build the wall. If one block doesn’t sit well, choose another block that does.  

🗹 Ensure tight fit between the blocks.  This reduces any potential gaps.  

🗹 Stagger the seams.  Alternate the seams for a stronger structure.  

🗹 Secure block walls.  If you are building walls over 5 feet high, you should anchor the backside to add stability to the wall.  

🗹 Check alignment:  Verify each block remains flush and level as you build.  

Proper anchoring ensures the system behaves as a single, continuous safety barrier, not a collection of loosely fitted blocks.

Tip #3:    Using Correct Tools to Cut Ballistic Rubber.   

The Problem

Ballistic Rubber is made from strong material which can take time to make cuts.  Take your time to ensure square edges.  

The Solution

Option 1:  Cut rubber blocks with a sharp utility knife and straight edge.  As cuts become deeper, add a wedge to open the cut area as you go.

Option 2:  When using power tools, choose a saw with a slow moving blade and medium blade.  Add a little water to cool the rubber if needed.

Edge protection is structural and a core part of ballistic safety. Consistent reinforcement keeps containment systems performing under pressure, round after round.

Tip #4:   Use Certified or Compatible Rubber Materials

The Concern 

Not all rubber is designed for ballistic containment. Some range builders use recycled playground or conveyor belt rubber to cut costs, assuming “rubber is rubber.” These materials are not tested for projectile velocity, density, or rebound characteristics and can fragment, melt, or even ignite under heavy use.

Why It Matters

Using uncertified materials undermines the entire safety system. Non-rated ballistic rubber wears quicker,  increases ricochet potential, and lead contaminates in the air are more difficult to clean and manage.  How to Avoid Choosing Wrong

🗹 Specify certified materials: Choose ballistic rubber rated for projectile absorption, penetration resistance, and temperature tolerance.

🗹 Source from verified suppliers: Partner with manufacturers that provide test data, certification, and quality control, such as TAP Ballistics.

🗹 Inspect shipments: Verify labeling, density, and finish before installation to confirm authenticity.

Certified ballistic rubber performs better, and it guarantees compliance, longevity, and consistent safety across the entire range system.

How TAP Ballistics Helps Ensure Safe and Compliant Installations

At TAP Ballistics, safety and precision are engineered into every product, but proper installation completes the system. Each component is designed to interlock seamlessly, absorb energy predictably, and meet the ballistic performance standards demanded by commercial, law-enforcement, and defense facilities around the world.  

Built for Performance and Compliance

🗹 Ballistic Blocks: Modular, stackable, and precision-molded to eliminate gaps and reduce ricochet. Ideal for both permanent and modular range configurations.

🗹 Bullet Trap Rubber: Use High-Density recycled rubber from semi truck tires for the berm rubber trap systems.  Tested for consistent energy absorption and minimal rebound.

🗹 Ballistic Range Panels: Durable composite panels that protect structural surfaces while maintaining a clean, professional range finish.

Every TAP product is manufactured to align with NRA Range Source Book guidelines, EPA lead-management practices, and OSHA. When installed correctly, these materials deliver long service life, predictable performance, and measurable compliance.

Whether you’re building a new facility or upgrading an existing range, partnering with TAP Ballistics means you’re supported by specialists who understand every layer of ballistic safety, from material science to installation integrity.

Build safer, last longer, and perform better with TAP Ballistics. Visit TAP Ballistics